Volkswagen Eurovan 2000-03

Removal & Installation

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NOTE
Be sure to obtain the anti-theft code for the radio.

  1. Disconnect the negative battery cable.
  2.  
  3. From inside the engine compartment, remove the dust/pollen filter.
  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Disconnect the heater hoses from heater core.
  8.  
  9. Remove the right side air intake duct at instrument panel.
  10.  
  11. Release the retaining tabs and pull out air vent housing for air intake duct.
  12.  
  13. Remove the radio trim panel.
  14.  
  15. Remove the hex bolts on both sides of the passenger-s side air bag unit and remove air bag.
  16.  
  17. Remove the hex bolt from the air duct and cross panel support in engine compartment behind vacuum reservoir.
  18.  
  19. Remove the driver side airbag by performing the following procedure:

    Place the steering wheel so front tires are facing straight-ahead.
     
    At the rear of the steering wheel, insert a 7 in. (175mm) screwdriver into the hole in the hub approximately 134
     
    Pull the screwdriver upward to release the air bag clip.
     
    Rotate the steering wheel 180 degrees in the opposite direction and release the clip on the other side.
     
    Center the steering wheel with the front wheels facing straight-ahead.
     
    Disconnect the electrical connector and remove the air bag.
     

  20.  
  21. Remove the steering wheel from the steering column by removing the center hex bolt.
  22.  
  23. Remove the instrument panel by performing the following procedure:

    Remove the upper steering column cover screws and the cover.
     
    Remove the lower steering column cover screws, release the steering wheel height adjustment and remove the lower steering column switch trim.
     
    Remove the combination switch-to-steering column bolt, disconnect the electrical connectors and remove the combination switch.
     
    Remove the 2 screws at the rear of the instrument cluster trim cover, press in the clips and remove the trim cover.
     
    Remove the 2 screws at the side of the speedometer cluster cover, pull the cover forward and disconnect the electrical connector.
     
    Below the instrument cluster, remove the fresh air vent and the vent outlet.
     
    Insert a thin feeler gauge above the headlight dimmer switch and push to the right to release the locks and then remove the dimmer switch.
     
    Remove the left and right center air outlets and the ashtray.
     
    Starting at the ashtray opening, carefully loosen the center instrument panel trim panel and remove the panel.
     
    Insert radio release tool 3316 into unlocking slots on side of radio until engaged.
     
    Remove radio from instrument panel by pulling out on tool.
     
    Disconnect radio connectors.
     
    Remove the A/C control head trim panel, remove 4 screws and the A/C control panel.
     
    Remove the heater control trim panel, the heater rotary knobs and remove the heater control panel.
     
    Disconnect all electrical connectors from the center instrument panel.
     
    At the driver-s side, remove the fuse/relay panel cover and the storage tray.
     
    At the driver-s side, remove the footwell air duct screws and the air duct.
     
    At the driver-s side, remove the A-pillar trim panel.
     
    At the driver-s side, remove the photosensor from the top of the instrument panel.
     
    Disconnect the radio speaker connectors from both sides of the instrument panel.
     
    On both sides of the instrument panel, remove the instrument panel end trim cover and remove the hex screws.
     
    Remove the instrument panel assembly from the instrument panel carrier.
     
    Remove the 3 heater core mounting bolts and remove the heater core.
     

  24.  


    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel, and related components-Eurovan


To install:

  1. Install the heater core to the heater housing.
  2.  
  3. Connect the heater hoses to the heater core.
  4.  
  5. Install the instrument panel by reversing the removal procedure.
  6.  
  7. Torque the steering wheel nut to 37 ft. lbs. (50 Nm). Torque the driver-s side air bag mounting screws to 44 inch lbs. (5 Nm).
  8.  


NOTE
Be sure to obtain the anti-theft code for the radio.

  1. Disconnect the negative battery cable.
  2.  
  3. From inside the engine compartment, remove the dust/pollen filter.
  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Disconnect the heater hoses from heater core.
  8.  
  9. Remove the right side air intake duct at instrument panel.
  10.  
  11. Release the retaining tabs and pull out air vent housing for air intake duct.
  12.  
  13. Remove the radio trim panel.
  14.  
  15. Remove the hex bolts on both sides of the passenger-s side air bag unit and remove air bag.
  16.  
  17. Remove the hex bolt from the air duct and cross panel support in engine compartment behind vacuum reservoir.
  18.  
  19. Remove the driver side airbag by performing the following procedure:

    Place the steering wheel so front tires are facing straight-ahead.
     
    At the rear of the steering wheel, insert a 7 in. (175mm) screwdriver into the hole in the hub approximately 1 3 / 4 in. (45mm) deep.
     
    Pull the screwdriver upward to release the air bag clip.
     
    Rotate the steering wheel 180 degrees in the opposite direction and release the clip on the other side.
     
    Center the steering wheel with the front wheels facing straight-ahead.
     
    Disconnect the electrical connector and remove the air bag.
     

  20.  
  21. Remove the steering wheel from the steering column by removing the center hex bolt.
  22.  
  23. Remove the instrument panel by performing the following procedure:

    Remove the upper steering column cover screws and the cover.
     
    Remove the lower steering column cover screws, release the steering wheel height adjustment and remove the lower steering column switch trim.
     
    Remove the combination switch-to-steering column bolt, disconnect the electrical connectors and remove the combination switch.
     
    Remove the 2 screws at the rear of the instrument cluster trim cover, press in the clips and remove the trim cover.
     
    Remove the 2 screws at the side of the speedometer cluster cover, pull the cover forward and disconnect the electrical connector.
     
    Below the instrument cluster, remove the fresh air vent and the vent outlet.
     
    Insert a thin feeler gauge above the headlight dimmer switch and push to the right to release the locks and then remove the dimmer switch.
     
    Remove the left and right center air outlets and the ashtray.
     
    Starting at the ashtray opening, carefully loosen the center instrument panel trim panel and remove the panel.
     
    Insert radio release tool 3316 into unlocking slots on side of radio until engaged.
     
    Remove radio from instrument panel by pulling out on tool.
     
    Disconnect radio connectors.
     
    Remove the A/C control head trim panel, remove 4 screws and the A/C control panel.
     
    Remove the heater control trim panel, the heater rotary knobs and remove the heater control panel.
     
    Disconnect all electrical connectors from the center instrument panel.
     
    At the driver-s side, remove the fuse/relay panel cover and the storage tray.
     
    At the driver-s side, remove the footwell air duct screws and the air duct.
     
    At the driver-s side, remove the A-pillar trim panel.
     
    At the driver-s side, remove the photo sensor from the top of the instrument panel.
     
    Disconnect the radio speaker connectors from both sides of the instrument panel.
     
    On both sides of the instrument panel, remove the instrument panel end trim cover and remove the hex screws.
     
    Remove the instrument panel assembly from the instrument panel carrier.
     
    Remove the 3 heater core mounting bolts and remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel, and related components-Eurovan

     

  24.  

To install:

  1. Install the heater core to the heater housing.
  2.  
  3. Connect the heater hoses to the heater core.
  4.  
  5. Install the instrument panel by reversing the removal procedure.
  6.  
  7. Torque the steering wheel nut to 37 ft. lbs. (50 Nm). Torque the driver-s side air bag mounting screws to 44 inch lbs. (5 Nm).
  8.  

EuroVan



Removal & Installation
Front System
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Remove the glove compartment.
  6.  
  7. Unclip the right air vent. Remove the screw holding the duct and remove the duct.
  8.  
  9. Remove the 3 screws retaining the air intake duct on the left side of the firewall, inside the engine compartment. Remove the duct.
  10.  
  11. Unclip the center air outlet vents. Remove the 2 screws retaining the center air outlet duct and remove the duct.
  12.  
  13. Remove the heater control cables from the heater box housing.
  14.  
  15. Disconnect the electrical harness connector from the fresh air blower series resistor.
  16.  
  17. Remove the 3 screws from the footwell air outlet cover and remove the cover.
  18.  
  19. Remove the 4 screws from the footwell air outlet console. Detach and remove the console.
  20.  
  21. Disconnect the cooling hoses from the heater core and plug the connections.
  22.  
  23. Remove the cable at the heater control valve.
  24.  
  25. Remove the 2 retaining screws from the heater box.
  26.  
  27. Remove the heater box housing.
  28.  
  29. Remove the 2 retaining screws and remove the heater core.
  30.  

To install:

  1. Install the heater core to the heater box.
  2.  
  3. Install the heater box and tighten the retaining screws.
  4.  
  5. Install the cable at the heater control valve.
  6.  
  7. Connect the cooling hoses to the heater core.
  8.  
  9. Install the footwell air outlet cover and console.
  10.  
  11. Connect the harness connector to the fresh air blower series resistor.
  12.  
  13. Install the cables to the heater/fresh air control.
  14.  
  15. Install the center air outlet and center air duct.
  16.  
  17. Install the air intake duct on the firewall.
  18.  
  19. Install the right air duct and the glove compartment.
  20.  
  21. Refill the cooling system.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  26.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Remove the glove compartment.
  6.  
  7. Unclip the right air vent. Remove the screw holding the duct and remove the duct.
  8.  
  9. Remove the 3 screws retaining the air intake duct on the left side of the firewall, inside the engine compartment. Remove the duct.
  10.  
  11. Unclip the center air outlet vents. Remove the 2 screws retaining the center air outlet duct and remove the duct.
  12.  
  13. Remove the heater control cables from the heater box housing.
  14.  
  15. Disconnect the electrical harness connector from the fresh air blower series resistor.
  16.  
  17. Remove the 3 screws from the footwell air outlet cover and remove the cover.
  18.  
  19. Remove the 4 screws from the footwell air outlet console. Detach and remove the console.
  20.  
  21. Disconnect the cooling hoses from the heater core and plug the connections.
  22.  
  23. Remove the cable at the heater control valve.
  24.  
  25. Remove the 2 retaining screws from the heater box.
  26.  
  27. Remove the heater box housing.
  28.  
  29. Remove the 2 retaining screws and remove the heater core.
  30.  

To install:

  1. Install the heater core to the heater box.
  2.  
  3. Install the heater box and tighten the retaining screws.
  4.  
  5. Install the cable at the heater control valve.
  6.  
  7. Connect the cooling hoses to the heater core.
  8.  
  9. Install the footwell air outlet cover and console.
  10.  
  11. Connect the harness connector to the fresh air blower series resistor.
  12.  
  13. Install the cables to the heater/fresh air control.
  14.  
  15. Install the center air outlet and center air duct.
  16.  
  17. Install the air intake duct on the firewall.
  18.  
  19. Install the right air duct and the glove compartment.
  20.  
  21. Refill the cooling system.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  26.  

Rear Auxiliary System
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Disconnect the wiring harness connector from the rear auxiliary heater.
  6.  
  7. Remove the coolant return hose and the coolant supply hose from the heater core.
  8.  
  9. Remove the 2 screws and unsnap the upper air outlet vent. Remove the 4 screws and remove the lower air outlet vent.
  10.  
  11. Remove the screws and remove the rear heater.
  12.  
  13. Remove the 2 retaining screws and remove the heater core.
  14.  

To install:

  1. Install the heater core and tighten the screws.
  2.  
  3. Install the rear heater assembly and tighten the screws.
  4.  
  5. Install the lower air outlet vent and tighten the 4 screws.
  6.  
  7. Snap the upper air outlet vent into place and tighten the 2 screws.
  8.  
  9. Install the coolant return and supply hoses to the heater core.
  10.  
  11. Connect the wiring harness to the rear heater.
  12.  
  13. Refill and bleed the cooling system.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Run the engine to normal operating temperatures. Check the climate control operation and check for leaks.
  18.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Disconnect the wiring harness connector from the rear auxiliary heater.
  6.  
  7. Remove the coolant return hose and the coolant supply hose from the heater core.
  8.  
  9. Remove the 2 screws and unsnap the upper air outlet vent. Remove the 4 screws and remove the lower air outlet vent.
  10.  
  11. Remove the screws and remove the rear heater.
  12.  
  13. Remove the 2 retaining screws and remove the heater core.
  14.  

To install:

  1. Install the heater core and tighten the screws.
  2.  
  3. Install the rear heater assembly and tighten the screws.
  4.  
  5. Install the lower air outlet vent and tighten the 4 screws.
  6.  
  7. Snap the upper air outlet vent into place and tighten the 2 screws.
  8.  
  9. Install the coolant return and supply hoses to the heater core.
  10.  
  11. Connect the wiring harness to the rear heater.
  12.  
  13. Refill and bleed the cooling system.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Run the engine to normal operating temperatures. Check the climate control operation and check for leaks.
  18.  

 
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